A Review of Power-Generating Turbomachines

Proceedings of the 2012 ASEE North Central Section Conference

Copyright © 2012, American Society for Engineering Education 1

A Review of Power-Generating Turbomachines

Joel Bretheim and Erik Bardy

Grove City College, Grove City, Pennsylvania 16127

Email: [email protected], [email protected]

Abstract A turbomachine is a device which interacts with a continuously flowing fluid by means of a

rotor, which results in either the extraction of energy from the fluid (as in turbines), or the

addition of energy to the fluid (as in compressors and pumps). Two major applications of

turbomachinery include power generation and propulsion. This paper presents an overview of

current and past developments of turbomachinery in power generation, as well as a review on

research involved in future developments. Specifically, turbines in the steam, gas combustion,

hydroelectric, ocean energy, and wind sectors are examined. In addition, a brief description of

the historical development of these various turbine types is included, as well as a discussion of

their current designs, with an emphasis on the rotor.

Current research topics related to steam turbines include computer modeling of two-phase flow

fields to reduce erosion in the machines, as well as the use of unsteady computational fluid

dynamics (CFD) packages to assess blade design with respect to aeroelastic instability, with the

goal of improving component lifespan and efficiency. In gas combustion turbines, current efforts

in sustainability are focused on identifying alternative fuels and reducing emissions, as dictated

by ever stricter environmental regulations. Hydraulic turbines employed in hydroelectric power

plants are subject to cavitation and its destructive effects. Researchers are using new CFD

analysis techniques to handle, reduce, or avoid cavitation in the flow of hydraulic turbines,

leading to better performance, efficiency, and cost-savings. On the ocean energy front (a largely

undeveloped but very promising source of renewable energy), researchers are adapting blade

element momentum theory (BEMT) performance models and the Reynolds-Averaged Navier

Stokes (RANS) equations to tidal turbine systems analysis and wave turbine systems with the

goal of increasing cost-competitiveness of ocean energy. Finally, the wind sector is addressed

with a discussion of current research in offshore wind turbines and wind turbine farm array

optimization.

The future development and research portion of the discussion is presented with an underlying

emphasis on efficiency, sustainability, and cost-savings.

Introduction This paper presents electrical-power generating turbines by flow-type; first compressible-flow

type turbines are examined in sections 1 and 2, followed by incompressible-flow type turbines in

sections 3 and 4, and then wind turbines in section 5. Each section addresses the historical

development, current usage and rotor design, as well as the status of current and future research

and development for each turbine type. The greatest research discussion is found in the sections

covering ocean and wind energy. These two energy sectors are in a state of growth now that

steam, gas, and hydraulic turbines are not, as they are older and more established technologies.

mailto:[email protected]

mailto:[email protected]



1.0 Steam Turbines

1.1 Past The idea of using steam to produce work has been around for centuries, dating back to the time

of Archimedes. It was not until the industrial revolution, however, that steam power started to

realize its potential in the form of reciprocating engines and turbines. The first impulse type

turbine was created by Carl Gustaf de Laval in 1883. This was closely followed by the first

practical reaction type turbine in 1884, built by Charles Parsons. Parsons’ first design was a

multi-stage axial-flow unit, which Westinghouse acquired and began manufacturing in 1895,

while General Electric acquired de Laval’s designs in 1897. Since then, development has sky-

rocketed from Parsons’ early design, producing 0.746 kW, to modern nuclear steam turbines

producing upwards of 1500 MW.1 Today, steam turbines account for roughly 90% of electrical

power generated in the United States.2

1.2 Current Design

Steam turbines can be designed for either radial- or axial-flow. Modern steam turbines are

predominantly axial-flow units, especially in large power plant applications. Steam and gas

turbines are both used extensively in power plants to drive electric generators, but steam turbines

are generally much larger in size. The rotors are generally multistage arrangements designed to

handle high pressures in the first stages and lower pressures in the later stages.3

The two major axial-flow turbine stage configurations are impulse and reaction. The distinction

is based upon relative pressure drop across the stage, where one stage consists of one row of

stationary blades/nozzles, and one row of rotating blades. A design is considered an impulse

design if most or the entire pressure drop occurs across the stationary blade or nozzle (a 0%

reaction). A reaction design experiences a pressure drop across both the stationary and rotating

blades. If the pressure drop is split equally between the stationary and rotating blades, the

reaction is 50%.1 As the steam flows across a stage its kinetic energy does work upon the

rotating blades. One tool important to the understanding of energy transfer from steam to rotor is

the velocity triangle.

Figure 1: a) Typical steam turbine stage1 b) Velocity triangle for a reaction turbine c) Velocity

triangle for an impulse turbine.3

In the impulse turbine design, the magnitude of the relative velocity of the steam remains

unchanged (W2 = W3), but the absolute velocity exiting the rotor is greatly reduced (V3 << V2).

The kinetic energy lost in the fluid has been transferred to the rotor and is proportional to the



difference in the squares of the velocities V2 and V3. The reaction design velocity triangle differs

from the impulse design in that W3 is much larger than W2. This increase in relative velocity

corresponds to a pressure drop across the rotating blades and a loss of enthalpy. A multistage

turbine can be designed to have each nozzle row coupled with one moving blade row (pressure

compounding), or have one nozzle row direct steam to multiple moving blade rows (velocity

compounding). There are also intermediary designs that incorporate both pressure and velocity

compounding.

1.3 Future Developments and Research

Recent developments and improvements in three-dimensional Computational Fluid Dynamics

(CFD) codes have allowed researchers to gain new insight into steam turbine problems.

Reliability is of critical importance in steam power generation1, and so current research

surrounding steam turbines is focused around a few fundamental areas, in particular, multiphase

flow and aeroelastics. Two-phase flow in steam turbines poses a significant problem for turbine

component lifespan and reliability due to water erosion, particularly in the final stages.

Researchers are using three-dimensional numerical simulation to study two-phase flow fields to

learn how to minimize water erosion.4,5,6

Blade flutter due to aeroelastic instability is another

significant concern in turbine reliability. These vibrations occur due to tip shrouds on the last

stage moving blades during high mass flow, which are necessary for performance reasons.

Researchers are using unsteady CFD packages to assess blade design and identify aeroelastic

stability margins for safe operation.7 Steam turbine design will continue to change as CFD

packages become more advanced and researchers put them to use.

2.0 Gas Combustion Turbines

2.1 Past

Steam turbines developed first around the time of the industrial revolution. It was not until the

1930s and 1940s that gas turbines began to be developed and utilized as aircraft engines. The

1960s saw the advent of gas turbines for power generation applications, particularly in peaking

power plants and co-generation plants (as supplements to the more conventional steam turbine

plants). Gas turbine technology increased rapidly to a unit size of 100 MW within 30 years.

Modern gas turbines generate upwards of 300 MW.8

2.2 Current Design

Gas combustion turbines are similar to steam turbines in that they are generally axial-flow

designs. Radial-flow gas turbines are considered simpler, and there are some applications for it,

but axial-flow designs are preeminent in aircraft and stationary power plants. The basic gas

turbine is comprised of three major components: a centrifugal

or axial-flow compressor (to compress the working gas from a

state of low pressure to high pressure), the combustor or heat

exchanger (to raise the exit gas-fuel mix temperature), and the

turbine itself (to extract energy from the working gas,

producing mechanical power). The compressor and turbine

are generally interdependent, operating off the same shaft.9

Like steam turbines, gas turbines find extensive use in power plants but are typically much

smaller in size. What really differentiates gas turbine combustion engines, and indeed where they

Figure 2: Simple gas turbine system.43



have made their greatest impact, is their application to aircraft propulsion. In aircraft gas

turbines, which are designed for efficiency as well as diameter and weight, a more sophisticated

design includes the following components: compressor (centrifugal or axial), fans, combustors,

turbine (radial or axial), ducts, air systems, nozzle guide vanes (NGVs), mixers, afterburners, and

heat exchangers.9 Typical configurations include shaft-powered (turboprops and turboshafts,

used for fixed-wing and rotary-wing aircraft, respectively) and thrust-propelled (turbojets,

turbofans, and ramjets). Typical gas turbine design is similar to that of a steam turbine, with one

stage being comprised of a row of nozzle guide vanes, and a corresponding row of rotor blades

mounted on a rotor disc connected to the main shaft.


Aside from improving efficiency, critical areas of research are fuel availability, fuel flexibility,

and emissions reduction. There is presently significant research being done on combustion

characteristics of alternative fuels such as ethanol10

, palm methyl ester (PME)11

, dimethyl ester

(DME)12

, hydrogen/syngas13,14

, and biofuels.15

Researchers are using 3D CFD codes to simulate

alternative fuel combustion flows and flame propagation within turbines and to analyze the fluid

dynamic effects.13,16

In addition to fuel research, researchers are turning

their attention more and more to emissions

reduction as tighter governmental regulations

necessitate.17

As turbine efficiency has increased

with increasing turbine inlet temperatures, so too

has NOx production which tends to increase with

inlet temperature. New engine and combustor

configurations are being investigated to address

these effects.

Another key advancement to the future of turbine

technology is turbine cooling of components in gas

turbine engines to achieve higher turbine inlet

temperatures.1 Increased inlet temperatures lead to

better performance and lifespan of the turbine. The thermodynamic ideal inlet temperature is

around 2000 °C, but even the most advanced metal alloys cannot operate above 980 °C; hence

the need for advanced cooling systems. Multiple-use alternative jet fuels are being researched

and developed to achieve the desired combustion efficiency, combustion stability, emission

levels, and even cooling properties.18

3.0 Hydroelectric/Hydraulic Turbines

3.1 Past

Energy has been extracted from flowing rivers and waterfalls for centuries, typically in the form

of rotating waterwheels. Today hydroelectric power stations use reservoirs to control and direct

flow over massive hydraulic turbines to produce electrical power on a grand scale. Very large

unit sizes exceeding 800 MW in capacity have been attained, along with efficiencies upwards of

95%.19

In 2007 approximately 36% of all renewable energy generated in the US came from

Figure 3: Axial turbine configuration.9



hydroelectric power plants (about six times the amount generated by wind and solar power plants

combined).20

3.2 Current Design

Rotor type and size is largely dependent on the specific speed (a variable resulting from the

combination of the head and power coefficients). Axial-flow turbines are best suited for high

specific speeds (2.0-5.0 for Kaplan turbines) where large flow areas are desired. They typically

operate at low heads with high flow rates. Radial-flow turbines are more suited for low specific

speed conditions (0.3-2.0 for Francis turbines) and typically operate at high heads with low flow

rates. The Pelton wheel is suited for the highest head applications with very small specific speed

in the range of 0.03 to 0.3.44

Figure 4: Impeller shape changes from radial to mixed to axial with increasing specific speed.44

Specific speed plays an important role in determining rotor geometry. As illustrated by Fig. 4,

the impeller shape changes as a function of specific speed. Also crucial to the rotor geometry is

the pressure drop seen by the fluid. The pressure drop is the distinguishing factor between two

main types of hydraulic turbine: the impulse and reaction turbine.

Impulse turbines, such as the Pelton wheel, are typically employed in situations where a large

potential energy is available. The potential energy is converted into kinetic energy as it flows

through large pipes (penstock) and finally through nozzles before impinging on the vanes or

buckets of the rotor. The force of the fluid impingement on the vanes/buckets creates a torque on

the shaft. Thus, all of the energy transfer between the fluid and the rotor occurs through impulse

action. The entire pressure drop occurs in the nozzles, resulting in no pressure drop as the fluid

flows through the rotor. The rotor, which is composed of multiple ellipsoidal or hemispherical

buckets positioned along the circumference, is not enclosed and remains at atmospheric pressure

throughout the whole process.44

Figure 5: Velocity triangle comparison for the a) Pelton wheel b) Francis turbine and c) Kaplan turbine where V1 is the

absolute velocity of the fluid, U is the vane speed, and W1 is the relative velocity.3

What distinguishes a reaction turbine from an impulse turbine is that a significant pressure drop

occurs across the rotor. In a reaction turbine, the rotor is enclosed and completely filled with the

working fluid (i.e. water). The water maintains significant kinetic energy and pressure after

passing through the rotor. The direction of water flow through in the runner determines the kind

of turbine. Francis turbines have water flow in the radial direction, while Kaplan turbines have

water flow in the axial direction.



In Francis designs the water flows through the penstock into a spiral casing and is directed by a

set of guide vanes on to the turbine rotor, called a runner. After flowing through the runner, the

water is discharged into the draft tube. Runner design is determined by certain key variables such

as operating head, required runner speed, speed ratio (blade velocity over fluid velocity), and

required runner output. In the Kaplan turbine, which is an axial-flow design best suited for high

flow rates, water is directed by stay vanes through wicket gates over a propeller turbine. The

propeller typically has five to eight blades. After passing through the blades, the water is

discharged through a draft tube.44

Figure 6: Voith Hydro schematics of the Pelton, Francis, and Kaplan hydraulic turbines (www.voithhydro.de).


A very important factor in research and development of hydraulic turbines is the handling,

reduction, or avoidance of cavitation in the flow, which results in decreased power output and

efficiency. Cavitation can also result in unwanted noise and vibration and contributes to gradual

erosive wear of the machinery, or even sudden catastrophic failure.19

Key to research efforts is the application of computational fluid dynamics (CFD), which began

about 30 years ago. CFD analysis has progressed in stages from 3D Euler solutions, to steady

RANS simulations using finite volume methods, to the present state of solving unsteady RANS

equations with advanced turbulence models.21

Now these tools are being developed to

incorporate two-phase flows, as in cavitation and free surface flow in Pelton turbines, the flow

simulation of which is considered “by far the most complex and difficult of all hydraulic

turbomachinery simulations”.22

Research is also prevalent on reaction turbines, which are generally considered more prone to

cavitation than impulse turbines. Researchers have applied these tools to the analysis and flow

simulation of Francis turbines with promising results that are beginning to converge and accord

with the experimental data.23

Researchers are also carrying out investigations on the acoustical

properties of cavitation in order to develop equipment monitoring systems that will accurately

estimate erosion level in the turbine.24

4.0 Ocean Energy Turbines (Tidal and Wave)

4.1 Past

The oceans of the earth represent an attractive alternative energy source. This source is

nonpolluting, more predictable than wind and solar, and vastly abundant. In fact, “The projected

available ocean power far exceeds the ultimate energy consumption of mankind”.25

Worldwide

http://www.voithhydro.de/



research and development, however, is relatively limited and lags far behind research into other

alternative energy resources.

The ocean stores energy for potential conversion into electricity in two primary ways: thermal

and mechanical. Thermal energy is available due to the temperature gradient from the surface of

the ocean to its depths. Solar irradiation incident on the ocean’s surface can lead to a temperature

gradient of 20 °C or more between the surface and depths of about 1000 meters in the equatorial

regions of the world’s oceans. Ocean Thermal Energy Conversion (OTEC) systems make use of

this temperature stratification as a heat engine to power the same kind of low-pressure steam

turbines discussed in section 1.2. While there has been promising research in OTEC systems

worldwide and especially in the U.S. since the 1960s onward, there are presently too many

challenges for OTEC systems to overcome to be economically feasible in the short-term, and the

U.S. Department of Energy no longer supports such research.20

In the short-term, there is more potential on the mechanical side of ocean energy for future

development in electricity-producing turbine systems. The ocean stores tremendous mechanical

energy in the forms of waves and tidal action, and both wave and tidal energy harnessing

systems have demonstrated economic feasibility for electricity production.20

The first tidal power

station was built in the 1960s on the estuary of the Rance River, off the northwestern coast of

France. The station, with an installed capacity of 240 MW, has operated very successfully and

reliably for years and yet remained the only industrial-scale tidal power station until the recent

completion of the Sihwa Lake tidal power station in South Korea. There are presently tidal

power installations in France, Russia, China, South Korea, and Canada. Wave energy systems

are even less developed than tidal systems.25

4.2 Current Design Tidal energy is typically harnessed to produce electricity in one of two ways: in-stream tidal

turbines and tidal barriers/dams.25

In-stream tidal turbines, which are relatively new technology,

are typically designed as large impellors housed in a shroud or duct. Newer designs, such as

those developed by Alstom/Clean Current (www.cleancurrent.com) and Irish company

OpenHydro (www.openhydro.com) feature open-center shaftless impellors, which increase both

performance and reliability. British company Marine Current Turbines

(www.marineturbines.com) has taken another approach, developing an in-stream tidal turbine

system that features multiple counter-rotating axial-flow pitch-controlled propeller rotors, similar

to those currently used in the wind industry. Other companies such as UEK Corporation in the

U.S. and Rotech in Scotland are developing their own unique approaches to harnessing tidal

stream energy via turbines.

http://www.cleancurrent.com/

http://www.openhydro.com/

http://www.marineturbines.com/



Figure 7: a) Open-center in-stream tidal turbine developed by OpenHydro (www.openhydro.com) b) in-

stream tidal turbine propeller rotor manufactured by Marine Current Turbines (www.marineturbines.com).

While in-stream tidal turbine systems use relatively new turbine rotor technology, tidal

barriers/dams can utilize conventional hydroelectric turbines. Specifically, the same kind of low-

head axial-flow turbines discussed in section 3. In tidal barrier/dam systems, water is collected

and stored in a reservoir at high tide, and then released through turbines at low tide. The

reservoir is created by a dam-like structure called a barrage and built in an estuary. Tidal

systems can also be designed with more complex two-way hydroelectric turbines that generate

electricity during both the reservoir charging and discharging stages. These setups rely on a

natural resonant inshore frequency for successful operation. Hence, the inshore geological

features are critically important. One downside is that power generation depends on the lunar

cycle, causing power generation to occur at different times on different days, and therefore not

always at the time of peak demand.20

Wave energy is less developed than tidal energy, but shows potential. While tidal systems can

utilize relatively conventional hydroelectric turbines, there are many different concepts for

mechanisms to extract energy from ocean waves. In particular, pneumatic turbines have found

application in ocean energy converting systems. Two such pneumatic turbine designs are the

Wells turbine and the McCormick turbine, which can be staged in co-rotating or counter-rotating

configurations.

The Wells turbine is unique in that its blades

have a symmetric profile. The overall reaction

force developed on the blade is perpendicular to

the overall approach flow, which is the vector

sum of the air flow velocity through the column

and the approach flow due to rotation. The useful

component of the overall reaction force is the

component in the direction of rotation and that

component is the driving force. Because of the

symmetric profile, once the turbine begins

rotating it will maintain its rotation even if the

direction of the air flow through the column changes. Wells turbines also find application in

Oscillating Water Columns (OWCs), another kind of wave energy device currently subject to

much research.26,27

Figure 8: Velocity triangle diagram of the forces developed

on the symmetric blade of a Wells turbine.39

http://www.openhydro.com/

http://www.marineturbines.com/



Another method to harness wave energy, used in Norway and developed by the Norwegian firm

Norwave, is the tapered channel method. This method employs a tapered channel to push water

over a barrier, where it is collected in a reservoir and then released through a low-head Kaplan

hydroelectric turbine. This method is similar to the tidal barrier method, however it is

specifically designed to use surface waves, which enter the channel and subsequently grow in

height as the channel narrows.25

4.3 Research and Future Developments

The previous three sections (1-3) covered the more traditional electricity-generating and well-

established technologies of steam, gas, and hydroelectric turbines. While research in these fields

is still active, the research and development in the ocean energy and wind energy fields are much

more prevalent right now, and accelerating rapidly.

Much of the research in ocean energy turbines is centered on adapting blade element momentum

theory (BEMT) performance models (long used in aircraft propulsion and wind turbine models)

and the Reynolds-Averaged Navier Stokes (RANS) equations to tidal turbine systems analysis

and wave turbine systems with the goal of increasing performance and cost-competitiveness of

ocean energy. Researchers in the UK have recently applied the RANS-BEMT approach to model

the wakes around tidal turbines and to study their effects on performance in turbine arrays.28,29

Their studies have identified highly effective strategies for lateral and longitudinal turbine row

spacing to enhance energy production, and in general have furthered understanding of turbine

wakes and their effects in different turbine array configurations.

Other researchers have adapted these BEMT models to incorporate the turbulent inflow

conditions present in coastal waters, where tidal stream turbines are likely to be deployed.30

Such

models allow engineers to accurately predict power output and other performance characteristics

without actual deployment. Similar research has been able to extend the models to account for

other real-world phenomena, such as tip and hub loss corrections.31

Such improvements and

specific-case modifications to BEMT models can lead researchers to ever more accurate models

and calculations of turbine performance in real-world flow conditions, driving up performance

and driving down cost for an overall increase in cost-competitiveness of ocean energy, which is

necessary for it to compete with existing fossil-fuel power plants.

Other researchers in Canada have developed numerical models to study the performance of

different configurations of twin-turbine tidal systems. Their model has been validated by

experimental tests and shown that power output of optimally-configured twin-turbine systems

can be more than twice the output of a single tidal turbine. They have also identified optimal

configurations for counter-rotating and co-rotating twin-turbine systems.32

Researchers have applied CFD codes to the analysis of Wells turbines in wave energy converting

systems. Examinations of the flow-fields around the turbine blades have yielded insights into

effects on performance by different tip clearances (uniform and non-uniform), with non-uniform

tip clearances generally leading to overall better performance.33

As tidal and wave turbine systems continue to grow in relevance to the world’s energy portfolio,

it is important to gauge their life cycle properties and determine how they compare to existing



technologies. Researchers in the UK have carried out cradle-to-grave assessments (including

emissions from starting materials all the way through the decommissioning and recycling of the

devices) of tidal and wave turbine systems and shown them to have comparable energy payback

periods, CO2 payback periods, and energy and carbon intensities when compared to each other.

They are also comparable to established technologies, such as wind turbines, and quite low when

compared to typical fossil fuel technologies. All ready at acceptable levels, life cycle properties

of tidal and wave systems only stand to get better as their construction methods and deployment

efficiencies improve.34

5.0 Wind Turbines

5.1 Past

Wind turbines are unique because, unlike the previously discussed turbomachines, they are not

enclosed and the rotor blades almost always lacks a stator, as well as other common components

like multiple stages, nozzles, inter-stage guide vanes, and compressors. These differences cause

some to not regard them as true turbines; however, they are operating under the same principles

and for the same end-purpose of electrical power generation. The modern wind turbine evolved

from the windmill (a purely mechanical device), which has been in use for centuries, most

notably in Europe. In the very late 1800s to early 1900s, the windmills were first adapted to

convert wind energy into electricity, creating the first true wind turbines.35

Electrical generators,

however, will not be addressed here. Wind turbine technology remained relatively dormant for

many years until the 1970s when research and development accelerated rapidly. Today, wind

turbines are viewed as a maturing technology with over 200 GW of installed electrical capacity

in over 80 countries.36

While onshore installations are now well-developed, many countries are now directing their

attention to offshore installations. The offshore wind resource is relatively untapped worldwide

and holds enormous potential for electricity-generating capacity.37

While offshore wind turbines

have been conceptualized for many years, the first realized offshore wind farm was not built until

1992 off the coast of Denmark. The first large, utility-scale offshore wind farm was not

commissioned until 2002. Today there is over 1000 MW of installed offshore wind capacity35

,

but offshore wind remains a largely untapped source of renewable energy and offers many

opportunities for research and development.

5.2 Current Design

The geometry of the rotor, which consists of a hub and blades, determines the basic classification

of a wind turbine. There are two basic classifications of a wind turbine: the horizontal-axis wind

turbine (HAWT) and the vertical-axis wind turbine (VAWT), distinguished by the orientation of

the rotor axis with respect to the oncoming flow of air. The rotors in HAWT devices, which are

more common than VAWT devices, are classified according to several factors including rotor

orientation, hub design, rotor control (pitch or stall), blade number (2 or 3), and yaw system.



Figure 9: a) Example velocity triangle diagram for a horizontal axis wind turbine b) example velocity

triangle diagram for a vertical axis wind turbine.3

While rotors can be designed to operate off the aerodynamic forces of lift or drag, the lift force is

the preferred method because lift-driven devices can achieve much higher apparent wind speeds

and thus can approach the theoretical maximum efficiency of 59% (the Betz limit).37

The

approach to rotor design in wind turbines has undergone an evolution in the last three decades.

The prevailing trend beginning in the 1980s was to maximize the design power coefficient of the

rotor for each given set of airfoils, but this resulted in undesirable efficiencies when operating in

off-design conditions. The 1990s saw a transition to rotor design centered on maximizing the

energy capture of the rotor by modifying blade characteristics to account for varying operating

conditions. The last decade saw a transition to rotor design centered on minimizing cost of

energy via complex optimization models, which factor in relevant data such as manufacturability

and site-specific environmental data.35

The rotor is the most important component of the wind turbine; therefore its design is critical.

Rotors can be designed as either upwind or downwind and typically have two or three blades, but

the most common configuration for the HAWT is the upwind rotor with three blades.35

Power

limitation is important in wind turbines, which have naturally fluctuating loads, and so rotors

must be designed with speed-regulation in mind. Two common designs for this are stall-

regulation and pitch-regulation. In stall-regulated designs, the blades are designed such that at a

certain critical wind speed the flow will separate from the low-pressure side of the blades,

resulting in stall. In pitch-regulated designs, the blades are designed such that they can be rotated

into and out of the wind in order to limit power. In recent years, pitch control has come to be the

dominant control mechanism.



Figure 10: Power limitation methods in wind turbine rotors: a) stall-regulation b) pitch-regulation.37

Also critical to rotor design is the choice of blade material. Fiberglass and carbon fiber

reinforced plastics (GRP and CFRP) are the most popular choice, with wood/epoxy laminates

finding use in some applications. Blade design is complex and depends on a number of different

design considerations: aerodynamic performance, structural strength, manufacturability, safety,

noise reduction and cost are just a few.35

5.3 Research and Future Developments

Wind turbine technology has experienced rapid growth over the last three decades and is now

considered a mature technology, especially in comparison to the more nascent ocean energy

sector. There remains little room for improvement in blades optimization and available land is

running out in the areas where wind energy is most developed, such as northern Europe. These

facts are necessitating two key areas of research: 1) wind farm layout optimization to make best

use of the land that is available and 2) offshore wind farm development.

In an effort to optimize wind farm layouts and wind farm power density, researchers in the state

of New York are developing a new methodology called Unrestricted Wind Farm Layout

Optimization (UWFLO) which optimizes farm layouts with varying turbine rotor diameters to

maximize net power output. The methodology employs a standard wake model, a must for farm

layout or grid optimization, and a stochastic optimization algorithm called Particle Swarm

Optimization (PSO). The new methodology has resulted in 30% increases in total power

generation via layout optimization and 43% increases via turbines with differing rotor

diameters.38

The vast majority of productive wind farms worldwide utilize HAWTs because of

their vast size, high power coefficient and multi-MW power output per unit, but such units

require significant swaths of land to operate properly. Researchers in California have turned their

attention to optimization of VAWT arrays, which require significantly smaller land area for

sizable power output and also utilize less vertical space, meaning less visual and radar impact.

The researchers conducted field studies of 10-meter tall VAWT arrays, arranged in counter-

rotating layouts and discovered that such layouts can utilize adjacent turbine wakes to actually

enhance performance. Power densities ranged from 21 to 47 W/m2 at wind speeds above the cut-

in speed, compared to the 2 to 3 W/m2 achieved by modern HAWT farms. This order-of-

magnitude enhancement bodes well for future efforts to efficiently use dwindling land resources

and to access land not suited for large HAWTs (typically on the order of 100 meters in height).39

Additionally, these researchers have shown that bio-inspired VAWT spatial arrangements based

on the studies of shed vortices in the wakes of schooling fish can lead to a significantly improved



array performance coefficient, whereas HAWT array performance always suffers due to closely

spaced turbines.40

As available land for traditional wind turbines diminishes, focus turns to offshore wind energy.

Many near-coastal regions of the ocean have ample available space and offer 40 to 50% more

energy yield compared to good land-based coastal sites.37

There are many differences between

offshore wind turbines and land-based wind turbines that must be considered, such as undersea

electrical transmission, wind farm design and layout, offshore operation and maintenance, and

the characteristics of the wind resource itself. One pronounced obstacle in designing offshore

wind turbines is designing suitable support structures, and this is one area where much current

research is directed. The two most common types of support structure are the monopile and

gravity structure, which both involve pile-driving into the seabed to support the turbine towers.

Researchers at the National Renewable Energy Laboratory (NREL) in Golden, Colorado have

used finite-element and aeroelastic computer codes to analyze the modal dynamics (loads and

instabilities) of these systems, which must be minimized for successful operation.41

Floating

support structures are less common but may be necessary for wind farm installations in deeper

seas. Researchers at NREL have recently conducted dynamic-response analyses of several

different floating support structure concepts for a 5 MW turbine. Their results show that tension-

leg platforms slightly outperform semisubmersible and spar buoy support structures, and all three

of these concepts outperform barge support structures in terms of the loads experienced by the

turbine and tower.42

Wind energy, an old technology, lay dormant for many years. The last 3 decades, however, have

witnessed a resurgence in wind turbine technology and it is far from over. The researchers at the

University of Massachusetts - Amherst, known for its wind energy research center, are currently

developing wind farm layout optimization (WFLO) models for offshore farms. Compared to

land-based wind farms, offshore models call for different optimization routines because of their

very different operation and maintenance characteristics and also different wind availability.

Two professors and researchers at the university, James Manwell and Jon McGowan, have

identified the following areas of research for future wind development:

improvements in electricity transmission from remote sites to end-use locations

reducing cost of energy at lower wind speed sites

commercial viability for turbine use in remote communities

offshore wind energy (still in its infancy with tremendous potential but many obstacles)

improvement of cost-effectiveness

new materials to increase turbine life (i.e. carbon fiber)35

Researchers at NREL and Sandia National Laboratories have outlined similar goals and are

currently working alongside industry to meet them. In addition to these research goals, the

general sizing of turbines stands to increase significantly in the future, with 5 MW turbines

already operational, 7 MW turbines soon to arrive, and possibly turbines with capacities of 10

and 20 MW not too far off.



Conclusion

Turbine technology is central to energy-producing efforts, whether they be well-established such

as steam, gas, or hydroelectric turbines, or new and emerging such as wave, tidal, and wind

turbines. Industry drives the research and development behind these technologies and as such,

most of that effort is directed towards cost-savings (increased efficiency, reliability, and

component lifespan), sustainability (alternative fuels, lower emissions), and cost-competitiveness

(particularly for the emerging technologies). One tool key to advancements in much of this

research is Computational Fluid Dynamics.

Bibliography 1 McCloskey, T.H., 2003, Handbook of Turbomachinery, 2

nd ed., Logan Jr., E., Ed., and Roy, R., Ed., Marcel

Dekker, Inc., New York, NY, Chap. 8 2 Wiser, W.H., 2000, Energy Resources, Springer-Verlag, New York, NY, Chap. 8

3 Logan Jr., E., 1981, Turbomachinery: Basic Theory and Applications, Marcel Dekker, Inc., New York, NY

4 Xie, D.; Shi, Y.; Li, W.; Hou, Y.; Yu, X.G.; and Qin, H.S., 2011, “Numerical simulation of wet steam two-phase

flow in the last-stage stationary blade of super-critical steam turbine”, 4th International Conference on Electric

Utility Deregulation and Restructuring and Power Technologies, pp. 771-775 5 Li, N.; Zhou, Q.; Chen, X.; Xu, T.; Hui, S.; and Zhang, D., 2008, “Liquid drop impact on solid surface with

application to water drop erosion on turbine blades, Part I: Nonlinear wave model and solution of one-

dimensional impact,” Int. J. Mechanical Sciences, 50(10-11), pp. 1526-1542 6 Zhou, Q.; Li, N.; Chen, X.; Xu, T.; Hui, S.; and Zhang, D., 2008, “Liquid drop impact on solid surface with

application to water drop erosion on turbine blades, Part II: Axisymmetric solution and erosion analysis,” Int. J.

Mechanical Sciences, 50(10-11), pp. 1543-1558 7 Rice, T.; Bell, D.; and Singh, G., 2009, “Identification of the stability margin between safe operation and the onset

of blade flutter,” Journal of Turbomachinery, 131(1), pp. 1-10 8 Termuehlen, H., 2001, 100 Years of Power Plant Development, ASME Press, New York, NY

9 Walsh, P.P. and Fletcher, P., 2004, Gas Turbine Performance, 2

nd ed., ASME Press and Blackwell Science,

Fairfield, NJ 10

Haas, F. M.; Chaos, M.; and Dryer, F.L., 2009, “Low and intermediate temperature oxidation of ethanol and

ethanol-PRF blends: An experimental and modeling study,” Combustion and Flame, 156(12), pp. 2346-2350 11

Hashimoto, N.; Ozawa, Y.; Mori, N.; Yuri, I.; and Hisamatsu, T., 2008, “Fundamental combustion characteristics

of palm methyl ester (PME) as alternative fuel for gas turbines,” Fuel, 87(15-16), pp. 3373-3378 12

Lee, M.C.; Seo, S.B.; Chung, J.H.; Joo, Y.J.; and Ahn, D.H., 2009, “Industrial gas turbine combustion

performance test of DME to use as an alternative fuel for power generation,” Fuel, 88(4), pp. 657-662 13

Miyama, N.; Inaba, K.; and Yamamoto, M., 2008, “Numerical simulation of tip leakage vortex effect on

hydrogen-combustion flow around 3D turbine blade,” Journal of Thermal Science, 17(2), pp. 186-192 14

Chaos, M.; and Dryer, F.L., 2008, “Syngas combustion kinetics and applications,” Combustion Science and

Technology, 180(6), pp. 1053-1096 15

Gupta, K.K.; Rehman, A.; and Sarviya, R.M., 2010, “Bio-fuels for the gas turbine: A review,” Renewable and

Sustainable Energy Reviews, 14(9), pp.2946-2955 16

Lu, T.F.; Yoo, C.S.; Chen, J.H.; and Law, C.K., 2010, “Three-dimensional direct numerical simulation of a

turbulent lifted hydrogen jet flame in heated coflow: A chemical explosive mode analysis,” Journal of Fluid

Mechanics, 652, pp. 45-64 17

Zhang, T.G. and Hou, X.Y., 2011, “NOx emission control in gas turbines,” Applied Mechanics and Materials, 66-

68, pp. 319-321, 2011 18

Mordaunt, C.J.; Kalaskar, V.B.; Mensch, A.; Santoro, R.J.; Lee, S.Y.; and Schobert, H.H., 2010, “Further studies

of alternative jet fuels,” Proceedings of the ASME International Mechanical Engineering Congress and

Exposition, 3, pp. 53-62 19

Arndt, R.E.A, 1998, The Handbook of Fluid Dynamics, Johnson, R.W., Ed., CRC Press, New York, NY, Chap. 41 20

Hodge, B.K., 2010, Alternative Energy Systems and Applications, John Wiley & Sons, Inc., Hoboken, NJ



21 Keck, H. and Sick, M., 2008, “Thirty years of numerical flow simulation in hydraulic turbomachines,”Acta

Mechanica, 201(1-4), pp. 211-229 22

Voith Hydro GmbH & Co. KG, n.d.,from http://www.voithhydro.com/vh_e_prfmc_pwrful_prdcts_turbines.htm 23

Wu, Y.; Liu, S.; Dou, H.S.; and Zhang, L., 2011, “Simulations of unsteady cavitating turbulent flow in a Francis

turbine using the RANS method and the improved mixture model of two-phase flows,” Engineering with

Computers, 27(3), pp. 235-250 24

Shi, H.; Chu, X.; Li, Z.; and Sun, Q., 2011, “Experimental investigations on cavitation in large Kaplan turbines,”

Proceedings of the 3rd International Conference on Measuring Technology and Mechatronics Automation, 2,

pp. 120-123 25

Takahashi, P. and Trenka, A., 1996, Ocean Thermal Energy Conversion, John Wiley & Sons Ltd, Chichester,

U.K. 26

Zhang, Y.; Zou, Q.P.; and Greaves, D., 2012, “Air-water two-phase flow modelling of hydrodynamic

performance of an oscillating water column device,” Renewable Energy, 41, pp. 159-170 27

Paixão C.J.M.; Teixeira, P.R.F.; and Didier, E., 2011, “Numerical simulation of an oscillating water column wave

energy converter: Comparison of two numerical codes,” Proceedings of the International Offshore and Polar

Engineering Conference, pp. 668-674 28

Turnock, S.R., 2011, “Modelling tidal current turbine wakes using a coupled RANS-BEMT approach as a tool for

analysing power capture of arrays of turbines,” Ocean Engineering, 38(11-12), pp. 1300-1307 29

Harrison, M.E., 2010, “A blade element actuator disc approach applied to tidal stream turbines,” MTS/IEEE

Seattle, OCEANS 2010 30

Togneri, M., 2011, “Incorporating turbulent inflow conditions in a blade element momentum model of tidal

stream turbines,” Proceedings of the International Offshore and Polar Engineering Conference, pp. 757-762 31

Masters, I., 2011, “A robust Blade Element Momentum Theory model for tidal stream turbines including tip and

hub loss corrections,” Proceedings of the Institute of Marine Engineering, Science and Technology Part A:

Journal of Marine Engineering and Technology, 10(1), pp. 25-35 32

Li, Y. and Calisal, S.M., 2009, “Modeling of twin-turbine systems with vertical axis tidal current turbines: Part

I—Power output,” Ocean Engineering, 37, pp. 627-637 33

Taha, Z.; Sugiyono; Tuan, Y.T.M.Y.S.; and Sawada, T., 2011, “Numerical investigation on the performance of

Wells turbine with non-uniform tip clearance for wave energy conversion,” Applied Ocean Research, 33(4), pp.

321-331 34

Walker, S. and Howell, R., 2011, “Life cycle comparison of a wave and tidal energy device,” Proceedings of the

Institution of Mechanical Engineers Part M: Journal of Engineering for the Maritime Environment, 225(4), pp.

325-327 35

Manwell, J.F., McGowan, J.G., and Rogers A.L, 2009, Wind Energy Explained: Theory Design and Application,

2nd

ed., John Wiley & Sons Ltd., West Sussex, U.K. 36

Kamada, R.F. and Mikkelsen, T., 2011, “Editorial: Trends in wind energy,” Journal of Renewable and Sustainable

Energy, 3, from http://dx.doi.org/10.1063/1.3656333 37

Graw, K.U., 2008, Renewable Energy: Sustainable Energy Concepts for the Future, Wengenmayr, R., and

Buhrke, T, Eds., Wiley-VCH, Weinheim, Germany, pp. 76-82 38

Chowdhury, S.; Zhang, J.; Messac, A.; and Castillo, L., 2012, “Unrestricted wind farm layout optimization

(UWFLO): Investigating key factors influencing the maximum power generation,” Renewable Energy, 38(1),

pp. 16-30 39

Dabiri, J.O., 2011, “Potential order-of-magnitude enhancement of wind farm power density via counter-rotating

vertical-axis wind turbine arrays,” Journal of Renewable and Sustainable Energy, 3(4) 40

Whittlesey, R.W.; Liska, S.; and Dabiri, J.O., 2010, “Fish schooling as a basis for vertical axis wind turbine farm

design,” Bioinspiration and Biomimetics, 5, pp.1-6 41

Bir, G. and Jonkman, J., 2008, “Modal dynamics of large wind turbines with different support structures,”

Proceedings of the 27th

International Conference on Offshore Mechanics and Arctic Engineering - OMAE, 6,

pp. 669-679 42

“Robertson, A.N. and Jonkman, J.M., 2011, “Loads analysis of several offshore floating wind turbine concepts,”

Proceedings of the 21st International Offshore and Polar Engineering Conference, p 443-450

43 Cohen, H., Rogers, G.F.C., and Saravanamuttoo, H.I.H., 1987, Gas Turbine Theory, 3rd ed., Longman Scientific

and Technical, Essex, U.K. 44

Murty, V.D., 2003, Handbook of Turbomachinery, 2nd

ed., Logan Jr., E., Ed., and Roy, R., Ed., Marcel Dekker,

Inc., New York, NY, Chap. 15

A Review of Power-Generating Turbomachines

Documents

Transcript of A Review of Power-Generating Turbomachines